Process for the preparation of 2-(6-substituted-1,-3-dioxane-4-YL) acetic acid derivatives

ABSTRACT

The invention relates to the preparation of 2-(6-substituted-1,3-dioxane-4-yl)acetic acid derivatives of formula 1, where X stands for a leaving group, and R 1 , R 2 , and R 3  each independently stand for an alkyl group with 1-3 carbon atoms from 4-hydroxy-6-X-substituted-methyl-tetrahydropyran-2-one compounds, where X is as defined above, with the aid of an acetalization agent, in the presence of an acid catalyst.  
     The invention also relates to the novel compounds of formula 1 as well as salts and acids to be prepared from these, with the OR 3  group in formula 1 being replaced by an OY group, where X, R 1  and R 2  have the meanings defined above and where Y stands for an alkaline (earth) metal or a substituted or unsubstituted ammonium group or stands for hydrogen, and to the novel compounds of formula 2. The products concerned are, after conversion into the t-butyl ester of 2-(6-hydroxymethyl-1,3-dioxane-4-yl)acetic acid, important as intermediary products in the preparation of statins.

The invention relates to a process for the preparation of a2-(6-substituted-1,3-dioxane-4-yl)acetic acid derivative of formula 1

where X stands for a leaving group, and R₁, R₂ and R₃ each independentlystand for an alkyl group with 1-3 carbon atoms, starting from a compoundof formula 2

where X is as defined above, use being made of a suitable acetalizationagent, in the presence of an acid catalyst.

The invention also relates to the new compounds of formula 1, as well assalts and acids of formula 3 that can be obtained therefrom

where R₁ and R₂ have the above-mentioned meanings and where Y stands foran alkaline (earth)metal or a substituted or non-substituted ammoniumgroup or stands for hydrogen.

Applicant has surprisingly found that the 2-(6-substituted1,3-dioxane-4-yl)-acetic acid derivative can be obtained selectively andin a high yield from the corresponding compound of formula (2), it beingpossible to prepare these products, which are relatively little stable,under mild conditions. This is all the more interesting since thisprovides a simple route via the corresponding salt, the correspondingt-butyl ester, and the 2-hydroxymethyl-substituted compound asintermediates in the preparation of HMG-CoA reductase inhibitors.Optionally the conversion proceeds (depending on the reaction conditionschosen) via an intermediary salt or ester, with the ring in the compoundaccording to formula (2) being opened.

An added advantage of the process according to the invention is thatboth the starting compounds of formula (2) and the products of formula 3are found to be crystalline compounds. This is advantageous in obtainingproducts with a (chemically and stereochemically) high purity. This isimportant in particular in view of the intended pharmaceuticalapplication. For the intended application in particular the(4R,6S)-2-(6-substituted-1,3-dioxane-4-yl)acetic acid derivative isimportant. It can be prepared from the corresponding6-substituted-2,4,6-trideoxy-D-erythrohexose. The invention, therefore,also relates to the starting compounds of formula 1, in particular whereX═Cl, and to particles of such compounds. In particular more than 90 wt.% of the particles has a length/diameter ratio between 1:1.5 and 1:6,preferably between 1:2 and 1:4.4 and a length of the particles between0.05 and 2 mm, in particular between 0.1 and 1 mm. The invention alsorelates to such particles. The compound of formula II gives clearcrystalline particles with a sharp melting point of 73-74° C. Theproducts of formula 3 derived from the(4R,6S)-2-(6-substituted-1,3-dioxane-4-yl)acetic acid derivative offormula 1 can according to the invention be prepared with anenantiomeric excess (e.e.) of more than 95%, in particular more than99.5%, and with a diastereomeric excess (d.e.) of more than 90%, inparticular more than 99.5%.

Examples of suitable leaving groups X that can be applied in the processaccording to the invention are halogens, in particular Cl, Br or I;tosylate groups; mesylate groups; acyloxy groups, in particular acetoxyand benzoyloxy groups; an aryloxy-, in particular benzyloxy-, or anitro-substituted benzene sulphonyl group. For practical reasons Cl ispreferably chosen as leaving group.

The groups R₁, R₂ and R₃ each separately stand for an alkyl group with1-3 carbon atoms, preferably methyl or ethyl. In practiceR₁=R₂=R₃=methyl is most preferred.

Examples of suitable acetalization agents that can be applied in theprocess according to the invention are dialkoxypropane compounds, withthe alkoxy groups each preferably having 1-3 carbon atoms, for instance2,2-dimethoxypropane or 2,2-diethoxypropane; alkoxypropene, with thealkoxy group preferably having 1-3 carbon atoms, for instance2-methoxypropene or 2-ethoxypropene. Most preferred is2,2-dimethoxypropane. This can optionally be formed in situ from acetoneand methanol, preferably with water being removed.

As acid catalyst use can be made of the acid catalysts known foracetalization reactions, preferably non-nucleophilic strong acids, forexample sulphonic acids, in particular p-toluene sulphonic acid, methanesulphonic acid of camphor sulphonic acid; inorganic acids with anon-nucleophilic anion, for example sulphuric acid, phosphoric acid:acid ion exchangers, for example DOWEX; or solid acids, for example theso-called heteropolyacids.

The acetalization can be carried out without using a separate solvent;if desired the reaction can also be carried out in an organic solvent.Examples of suitable organic solvents are ketones, in particularacetone, hydrocarbons, in particular aromatic hydrocarbons, for exampletoluene, chlorinated hydrocarbons, for example methylene chloride.

The temperature at which the acetalization reaction is carried outpreferably lies between −20° C. and 60° C., in particular between 0° C.and 30° C. The acetalization reaction is preferably carried out under aninert atmosphere.

The molar ratio of acetalization agent to starting compound of formula(2) preferably lies between 1:1 and 20:1, in particular between 3:1 and5:1. Using an organic solvent the molar ratio is in particular between1:1 and 2:1.

The molar ratio of acid catalyst to starting compound of formula (2)preferably lies between 1:1 and 0.001:1, in particular between 0.01:1and 0.05:1.

The resulting 2-(6-substituted-1,3-dioxane-4-yl)acetic acid derivativecan subsequently be hydrolyzed in the presence of a base and water toform the corresponding salt of formula 3

where Y stands for an alkaline metal, an alkaline earth metal, or asubstituted or unsubstituted ammonium group, preferably Na, Ca or atetraalkyl-ammonium compound. Optionally; the hydrolysis is followed byconversion to the acetic acid according to formula 3 with Y═H.

The hydrolysis of the compound of formula (3) is preferably carried outwith at least 1 base equivalent, in particular 1-1.5 base equivalents,relative to the compound of formula (3). In principle a larger excesscan be used, but in practice this usually does not offer any advantages.

The reaction is preferably carried out at a temperature between −20° C.and 60° C., in particular between 0° C. and 30° C.

The hydrolysis can for example be carried out in water, an organicsolvent, for example an alcohol, in particular methanol or ethanol, anaromatic hydrocarbon, for example toluene, or a ketone, in particularacetone or methyl isobutyl ketone (MIBK), or a mixture of an organicsolvent and water, optionally catalysed by a phase transfer catalyst(PTC) or addition of a cosolvent.

The hydrolysis can also be carried out enzymatically, the desireddiastereomer optionally being hydrolyzed selectively.

Examples of enzymes that can suitably be used in the process accordingto the invention are enzymes with lipase or esterase activity, forexample enzymes from Pseudomonas, in particular Pseudomonas fluorescens,Pseudomonas fragi; Burkholderia, for example Burkholderia cepacia;Chromobacterium, in particular Chromobacterium viscosum; Bacillus, inparticular Bacillus thermocatenulatus, Bacillus licheniformis;Alcaligenes, in particular Alcaligenes faecalis; Aspergillus, inparticular Aspergillus niger, Candida, in particular Candida antarctica,Candida rugosa, Candida lipolytica, Candida cylindracea; Geotrichum, inparticular Geotrichum candidum; Humicola, in particular Humicolalanuginosa; Penicillium, in particular Penicillium cyclopium,Penicillium roquefortii, Penicillium camembertii; Rhizomucor, inparticular Rhizomucor javanicus, Rhizomucor miehei; Mucor, in particularMucor javanicus; Rhizopus, in particular Rhizopus oryzae, Rhizopusarhizus, Rhizopus delemar, Rhizopus niveus, Rhizopus japonicus, Rhizopusjavanicus; porcine pancreas lipase, wheat germ lipase, bovine pancreaslipase, pig liver esterase. Preferably, use is made of an enzyme fromPseudomonas cepacia, Pseudomonas sp., Burkholderia cepacia, porcinepancreas, Rhizomucor miehei, Humicola lanuginosa, Candida rugosa orCandida antarctica or subtilisin. If an enantioselective enzyme is used,even further enantiomer enrichment is realized during the hydrolysis.Such enzymes can be obtained using commonly known technologies. Manyenzymes are produced on a technical scale and are commerciallyavailable.

The salts (acids) obtained are novel. The invention therefore alsorelates to these products of formula 3

where X stands for a halogen, in particular Cl, Br or I, a tosylate ormesylate group, an acyloxy group with 3-10 carbon atoms, or anitro-substituted benzene sulphonyl group and Y stands for H, analkaline (earth) metal, or a substituted or unsubstituted ammoniumgroup.

The resulting salt of formula 3 can subsequently be converted into thecorresponding t-butyl ester (formula 1a with R₃=t-butyl), in a way knownper se.

In the process according to the invention the compound of formula (3)can for example be esterified to form the corresponding tert. butylester using the following methods, which in general are described inliterature:

-   -   reaction with isobutene and strong acid, for example paratoluene        sulphonic acid (pTS), sulphuric acid or a strongly acidic ion        exchanger (U.S. Pat. No. 3,325,466);    -   reaction via the acid chloride and t-butanol, under the        influence of a base, for example triethylamine (Et₃N),        dimethylamino pyridine (DMAP). The acid chloride can be prepared        with the aid of for example SOCl₂, POCl₃, (COCl)₂ and catalyzed        by for example dimethyl formamide (DMF) (J. Org. Chem. 35 2429        (1970));    -   reaction via the acid chloride with Li-t-butanolate (Org. Synth.        51 96 (1971));    -   transesterification with t-butyl acetate under the influence of        a strong acid (Z. Chem. 12(7) 264 (1972));    -   reaction of the salt with t-butyl bromide, preferably in DMF,        dimethyl acetamide (DMAA), 1-methyl-2-pyrrolidinone(NMP) and        using a phase transfer catalyst (PTC) (Tetr. Let. 34 (46) 7409        (1993));    -   reaction of the acid with t-butanol, 1,3-dicyclohexyl        carbodiimide (DCC) and DMAP (Synth. Comm. 9, 542 (1979));    -   reaction of the acid with t-butyl-trichloro acetamidate (Tetr.        Let. 39, 1557 (1998));    -   reaction of the salt with carboxyl diimidazole (CDI) and        t-butanol;    -   reaction of the acid with pivaloyl chloride and t-butanol under        the influence of DMAP or N-methyl-morpholin (NMM) (Bull. Chem.        Soc. Japan 52 (7) 1989 (1979));    -   reaction of the salt with di-tert. butyl dicarbonate, DMAP and        t-butanol (Synthesis 1063 (1994));    -   reaction of the acid with cyanuric chloride and pyridine or        triethylamine (Org Process R&D 3, 172 (1999); Heterocycles 31        11, 2055 (1990)).

The resulting t-butyl ester of 2-(6-substituted-1,3-dioxane-4-yl)aceticacid can subsequently be converted into the2-(6-hydroxymethyl-1,3-dioxane-4-yl)acetic acid, for example asdescribed in U.S. Pat. No. 5,594,153 or in EP-A-1024139, in the presenceof a tetraalkyl ammonium halogenide and/or a carboxylic acid in thesalt, via conversion into a compound of formula 1a with R₃=t-butyl andX=an acyloxy, for example an acetoxy group. The acyloxy group cansubsequently be converted via solvolysis, in a way otherwise generallyknown, to a hydroxyl group. The solvolysis can be performed using a base(Na₂CO₃, K₂CO₃, or sodium methanolate in methanol), optionally bysimultaneous distillation of the methyl acetate formed.

The t-butyl ester of 2-(6-hydroxymethyl-1,3-dioxane-4-yl)acetic acid isa desirable intermediate product in the preparation of various statins,for example ZD-4522, as described in Drugs of the future, (1999), 24(5),511-513 by M. Watanabe et al., Bioorg. & Med. Chem. (1997), 5(2),437-444. The invention therefore provides a novel, interesting route tothese intermediate products and to the end products, in particularstatins.

The starting compounds of formula 2 can for example be obtained asdescribed in WO-A-96/31615.

The invention will be elucidated with reference to the followingexamples, without however being restricted by these.

EXAMPLE I Preparation of(4R,6S)-4-hydroxy-6-chloromethyl-tetrahydropyran-2-one (Compound II;Covered by Formula 2)

At room temperature 2.1 ml bromine was added in 45 minutes to a mixtureof 6.7 g (40 mmol) 6-chloro-2,4,6-trideoxy-D-erythro-hexose (compound I;prepared according to the method described in WO-A-96/31615) and 6.7 gsodium bicarbonate in 40 ml methylene chloride and 10 ml water. CO₂ gasescaped, while the pH remained at 5. After stirring for one hour,according to gas-liquid chromatography (GLC) the starting material hadbeen fully converted. The bromine excess was neutralized with solidNa₂S₂O₃. After phase separation the water phase was extracted with 2times 100 ml ethyl acetate. The combined organic phases were dried overNa₂SO₄ and filtered. After rotavap evaporation 5.5 g yellow oil wasobtained (82% yield of the compound of formula (2) with X═Cl relative tocompound I).

¹H NMR (200 MHz, CDCl₃): δ 1.8-2.1 (m, 2H); 2.6-2.7 (m, 2H); 3.5-3.8 (m,2H(CH₂Cl)); 4.4 (m, 1H); 4.9 (m, 1H).

EXAMPLE II Preparation of(4R,6S)-4-hydroxy-6-chloromethyl-tetrahydropyran-2-one (Compound II;Covered by Formula 2)

To a solution of 75 g (450 mmole) compound I in 390 ml water was added114 g (715 mmole) of bromine at 15-25° C. in 3 hours. The pH of thereaction mixture was maintained at 5-6 via the simultaneous addition ofsodium carbonate (88 g total amount). The excess of bromine wasneutralized with sodium bisulfite. The product was extracted from thewater phase with ethyl acetate (counter-current extraction).

The product was crystallized from ethyl acetate/heptane (125 g/62 g).After cooling to 0° C., the crystals were filtered, washed with 50 ml ofheptane/ethyl acetate (w:w=9:1) and dried, yielding 49.2 g (67% relativeto compound I) of compound II as colourless needles (m.p. 73-74° C.).

EXAMPLE III Preparation of(4R-cis)-6-(chloromethyl)-2,2-dimethyl-1,3-dioxane-4-yl Acetic AcidMethyl Ester (Compound III)

5.5 g of compound II as obtained in example I was added to 20 mlcommercial dimethoxy propane and 100 mg p-toluene sulphonic acidmonohydrate at room temperature. After stirring for one hour at roomtemperature GLC analysis showed that full conversion had taken place anda clear solution had been formed. After addition of 500 mg NaHCO₃stirring took place for 30 minutes at room temperature. After filtrationand rotavap evaporation 7.1 g compound III was obtained as alight-yellow oil (91% relative to compound II).

¹H NMR (200 MHz, CDCl₃): δ 1.25 (dt, 1H); 1.40 (s, 3H); 1.47 (s, 3H);1.79 (dt, 1H); 2.42 (dd, 1H); 2.58 (dd, 1H); 3.40 (dd, 1H); 3.52 (dd,1H); 3.70 (s, 3H); 4.1 (m, 1H); 4.35 (m, 1H).

EXAMPLE IV Preparation of(4R-cis)-6-(chloromethyl)-2,2-dimethyl-1,3-dioxane-4-yl Acetic AcidMethyl Ester (Compound III)

To a solution of 49.2 g (300 mmole) of compound II in 100 ml of toluenewas added 47 g (450 mmole) dimethoxy propane and 850 mg p-toluenesulphonic acid monohydrate (4.5 mmole).

After stirring for one hour at room temperature, GLC analysis showedcomplete conversion of compound II.

The toluene phase was washed with 50 ml of a 0.2N NaOH solution inwater. After evaporation 67 g of compound III was obtained as alight-yellow oil (94% relative to compound II).

EXAMPLE V (4R-cis)-(6-chloromethyl)-2,2-dimethyl-1,3-dioxane-4-yl-aceticAcid, Sodium Salt (Compound IV)

55 g (233 mmol) of compound III was added to 200 ml water. At roomtemperature 20 g of a 50% NaOH solution in water was added dropwise in 2hours at pH=12. The hydrolysis was monitored using GLC. After 20 g thepH remained constant. Concentrated hydrochloric acid was used to lowerthe pH to 10. The water phase was washed with 100 ml ethyl acetate andevaporated using a rotavap. The oil formed was dried by stripping withabsolute ethanol and toluene. The solid was stirred into 200 ml acetone,filtered and washed with cold acetone. Yield after vacuum drying: 45.6g=80% Na salt relative to compound III.

¹H NMR (200 MHz, CDCl₃/CD₃OD): δ 1.21 (dt. 1H); 1.36 (s, 3H); 1.49 (s,3H); 1.79 (dt, 1H); 2.25 (dd, 1H); 2.45 (dd, 1H); 3.46 (m, 2H); 4.11 (m,1H); 4.36 (m, 1H).

EXAMPLE VI(4R-cis)-(6-chloromethyl)-2,2-dimethyl-1,3-dioxane-4-yl-acetic Acid,Sodium Salt (Compound IV)

Starting from 49.2 g compound I, a solution of compound III in toluenewas prepared as described in example IV.

5 g methanol and 25 ml of water were added. At room temperature 25 g ofa 50% solution of NaOH in water was added dropwise in 1 hour.

After stirring for 4 hours at room temperature, GLC analysis indicatedcomplete hydrolysis.

The excess of base was neutralized to pH 8.5-9.5 with 33% HCl solutionin water. The waterphase was separated and dried via azeotropicdistillation using 470 ml of toluene, yielding 65 g compound IV as a 16w/w % suspension in toluene with KF<0.1%.

The suspension can be used for the synthesis of compound V.

EXAMPLE VII (4R-cis)-(6-chloromethyl)-2,2dimethyl-1,3-dioxane-4-yl-acetic Acid, t-butyl Ester (Compound V)

45.5 g IV, sodium salt (186 mmol) was added to a solution of 159 gditert. butyl dicarbonate in 1400 ml dry tert. butanol. After additionof 6.8 g dimethylamino pyridine stirring took place for 16 hours at 40°C. The reaction mixture was poured out into 1500 ml ethyl acetate and1000 ml saturated ammonium chloride. The water phase was re-extractedwith 1500 ml ethyl acetate. The combined organic phases were washed with600 ml saturated NaCl solution. The organic layer was dried over Na₂SO₄,filtered and then evaporated under vacuum, yielding 51.9 g yellow oil(100% relative to compound IV).

¹H NMR (200 MHz, CDCl₃): δ 1.15-1.33 (m, 1H); 1.40 (s, 3H); 1.45 (s,3H); 1.47 (s, 9H) 1.77 (dt, 1H); 2.33 (dd, 1H); 2.46 (dd, 1H); 3.40 (dd,1H); 3.49 (dd, 1H) 4.08 (m, 1H); 4.28 (m, 1H).

EXAMPLE VIII(4R-cis)-6-[(acetoxy)methyl]-2,2-dimethyl-1,3-dioxane-4-yl-acetic Acid,t-butyl Ester (Compound VI)

Starting from 33 g of compound V obtained according to example VII, in16 hours 29 g of compound VI was obtained at 100° C. according to U.S.Pat. No. 5,457,227 (using 40 g tetra-n-butyl ammonium acetate and in 200ml DMF), as a solid after crystallization from 75 ml heptane.

¹H NMR (200 MHz, CDCl₃): δ 1.1-1.3 (dt, 1H); 1.39 (s, 3H); 1.45 (s, 9H);1.47 (s, 3H); 1.57 (dt, 1H); 2.08 (s, 3H); 2.32 (dd, 1H); 2.46 (dd, 1H);4.0-4.2 (m, 3H); 4.3 (m, 1H).

EXAMPLE IX(4R-cis)-6-[hydroxymethyl]-2,2-dimethyl-1,3-dioxane-4-yl-acetic Acid,t-butyl Ester (Compound VII)

Starting from 29 g of compound VI according to example V, 25.0 gcompound VII was obtained as a light-yellow oil with e.e. =100%,d.e.=99.9% (according to GLC) according to U.S. Pat. No. 5,457,227 (usebeing made of 6.9 g potassium carbonate in 300 ml methanol).

¹H NMR (200 MHz, CDCl₃): Spectrum was in line with literature (Synthesis1014, 1995).

1-15. (canceled)
 16. A compound of formula (3),

each R₁ and R₂ is independently an alkyl group with 1-3 carbon atoms;and Y is an alkaline metal, an alkaline earth metal, or a substituted orunsubstituted ammonium group; wherein X is a tosylate group, a mesylategroup, an acyloxy group, an aryloxy-substituted benzene sulfonyl group,or a nitro-substituted benzene sulfonyl group; or wherein X is halo andsaid compound has an enantiomeric excess of 4R,6S of more than 95%. 17.The compound of claim 16, wherein X is halo.
 18. The compound of claim17, wherein said compound has an enantiomeric excess of more than 99%.19. The compound of claim 16, wherein said compound has a diastereomericexcess of more than 90%.
 20. The compound of claim 19, wherein saidcompound has a diastereomeric excess of more than 99%.
 21. The compoundof claim 16, wherein Y is Na, Ca or tetraalkyl ammonium.
 22. Thecompound of claim 16, wherein X is a tosylate group, a mesylate group,an acyloxy group with 3-10 carbons, an aryloxy-substituted benzenesulfonyl group, or a nitro-substituted benzene sulfonyl group.
 23. Thecompound of claim 22, wherein said compound is in the 4R,6S form. 24.The compound of claim 23, wherein said compound has an enantiomericexcess of more than 90%.
 25. The compound of claim 24, wherein saidcompound has an enantiomeric excess of more than 99%.
 26. The compoundof claim 16, wherein each R₁ and R₂ is independently methyl.
 27. Acompound of formula (1),

each R₁, R₂ and R₃ is independently an alkyl group with 1-3 carbonatoms; and wherein X is a tosylate group, a mesylate group, anaryloxy-substituted benzene sulfonyl group, or a nitro-substitutedbenzene sulfonyl group; or wherein X is halo or acyloxy and saidcompound has a particle length/diameter ratio between 1:1.5 and 1.6, anda particle length between 0.05 and 2 mm.
 28. A compound having formula(2) in the (4R,6S) form,

where X is a tosylate group, a mesylate group, an acyloxy group, anaryloxy-substituted benzene sulfonyl group, or a nitro-substitutedbenzene sulfonyl group.
 29. The compound of claim 28, having a particlelength/diameter ratio between 1:1.5 and 1:6.
 30. The compound of claim28, having a particle length between 0.05 and 2 mm.
 31. The compound ofclaim 28, having a particle length between 0.1 and 1 mm.
 32. Thecompound of claim 28, wherein said acyloxy group comprise 3-10 carbons.33. A compound having formula (2) in the (4R,6S) form

where X is halo, and wherein said compound has a particlelength/diameter ratio between 1:1.5 and 1.6, and a particle lengthbetween 0.05 and 2 mm.
 34. The compound of claim 33, wherein X ischloro.
 35. The compound of claim 33, having a particle length between0.1 and 1 mm.